Concrete construction



Feb. 24. 1925 0. A. HOLLIS CONCRETE CONSTRUCTION Original Filed'Jan. 13, 192 3 sheets sheet 1 I N w: NTOK lWx-rwesa Feb. 24. 19.25.

0. A. HOLLIS CONCRETE CONSTRUCTION 3 Sheets-Sheet 2 Original Filed Jan. 13, 1922 Feb. 241. i925.

0. A. HOLLIS comrmw CONSTRUCTION 3 Sheets-Sheet 5 Original Filed Jan. 13, 1922 luvs uroa wagw.

Patented Feb. 24, 1925.

UNlTED STATES PATENT OFFICE.

OTIS A. Bonus, on KNOXVILLE, PENNSYLVANIA.

cononnrn consrnnorion.

Application fil ed January 13, 1922, Serial No. 529,025. Renewed July 29, 1924.

To all whom it may concern:

lie it known that I, ,0 Is A. HoLLIs, a citi zen oi the United States, and residing in the borough of Knoxville, in the cpunty of AL legheny and State ol l cnnsylvania, have invented or discovered the new, useful, and improved Concrete Construction, of which the :lfollowing is a specification,

My invention consists of anew and im proved system of concrete construction and is especially applicable to walls.

The object which I have in view is the provision of a method of concrete construction which will permit rapid and convenient erection and will enable the use of a minimum of material to obtain a maximum of strength.

I provide a novel cellular, monolithic concrete structure or wall.

it provide a new and improved type of term or matrix structure which is inexpensive, of light weight and therefore easy to handle and which greatly facilitates the work. My matrix structure is self-leveling and self-centering.

It also provide a new and improved method of reinforcement whereby a cellular, monolithic structure may be constructed with increased strength as compared to a solid structure. The novel form of reinforcement costs a mere traction of the expense oi? a wall reinforced by the methods now in use.

I show new and improved processes or" imparting to the concrete structure a finished or ornamental surface. 7

Other novel and improved features will appear from the following description.

in the accompanying drawings. which are, however, merely intended to illustrate a practical embodiment of the principles of my invention without limiting the scope of the latter lo the coi'istruction shown, Fig. l is a perspective ot the corner oi a wall being constructed in accordance with the principl of my invention; 1'' 2 is a vertical cross e'tion of the same; F 3 is a sectional perspective of a portion of the wall illustrating the novel form of metal rein tor-cement; Fig. 4 is an enlarged detail in perspective showing one of the spreader bars and one of the vertical stays which I use in connection with the building of a wall; Fig.

5 is a sectional view of the same; Figs. 6, '7 andfi are sectional views of walls showing various characters. of hollow construction whichi use; Fig tlf-shows a matrix board withTani ornamental tile mounted on its working surface for embedding in the wall; Fig. 10 is a sectional view of a wall in course ct construction showing the method of applying an exterior or finishing layer of ornamental material in plastic form as the wall is built; Fig. 11 is a front elevation of the same; Fig. 12 is an enlarged plan view of one of the standard spreader bars the same being arranged to permit plastic surfacing and wall end construction, in Figs. 10 and 11, and in Figs. 16 and 17; Fig. 13 is an enlarged side elevation of one of the topspacers used in this form of surfacing; Fig. 14 is a broken elevation of one oi the wooden matrix boards; Fig. 15 is an elevation of a convenient form of metal matrix plate; Fig. 16 is a top plan view showing the end of a wall being constructed by my system, and Fig. 17 is an end view showing the arrangement of spreader bars and stay rods in such cases.

The following is a detailed description of the drawings, referring first to Figs. 1 to 5 inclusive.

The wall is built up vertically step by step by means of inner and outer matrix boards A which are held in position by means of spreader bars 13 and vertical stays C. Thus in Fig. 1 I show three superimposed courses, and for the sake of clearness l have indicated the lowermost matrix boards as A, the next above as A and the top boards as 1 the spreader bars are similarly indicated as B, 13?, B and B The stays are indicated as C and C As the wall or other structure rises, the matrices are removed from below from the courses in turn as they set and erected above.

In building the wall I first cast a foo-ting or foundation D having a truly horizontal top surfzue and of the proper dimensions and contour for the finished wall or building. Thus in Fig. 1, I have shown a corner or angle in the wall. i

I then lay transversely on said foundation the proper number of cross spreader bars B with their ends protruding at the outer and lnner sides ot the toundation. I next place in position the vertical stay rods C with their lower ends stepped in the holes 1 in the ends of the bars B and held in position by the metal pins or wire nails 2- ex tending through registering horizontal holes 3 and at in the bars and stays, respectively.

I then connect the upper ends of the opposed pairs of stay rods by means of spreader bars B which are pinned on the rods at a height equal to twice the width of a matrix board. The matrix boards A are now placed in position with their lower edges notched, as at 5, to fit down over the bottom spreader bars 13 and resting on the foundation wall D which is usually wider than the wall proper, to form a footing.

The concrete is now cast between the matrix boards A and levelled off horizontally, flush with the top of tlie matrix boards.

The spreaders B are now unpinned and dropped down so that they rest on the top edges of the matrix boards A and upon the top of the concrete filled in between said boards and are pinned to the stay rods C.

The next set of spreader bars l3 are now mounted on and pinned to the upper ends of the stay rods a. distance above the-spreaders B equal to twice the width of a matrix board, as shown in solid lines in Fig. 2, wherein the upper ends of the stay rods are broken to save room. The matrix boards A are now placed in position with their notched lower edges fitting down over the spreader bars B and resting on the top edges of the matrix boards A. The concrete is then filled in between the boards A and flush with the top edges of the same, as before, and the spreader bars B are then unpinned and dropped downv onto the tops of the matrix boards A and pinned to the stay rods.

In Fig. 1 I have shown the third course of concrete completely cast, and, in solid lines, the spreader bars B in their elevated posi tion while said bars are shown in dotted lines dropped into their lowered position on top of the matrix boards A preparatory to placing in position the next course of matrix boards.

The boards which meet to form the corner angle of the wall or structure, both inside and outside, may be provided with staples or eyelets 6 for the application of the metal angle braces E whose downwardly hooked ends engage the eyelets 6 and thus hold the ends of the corner boards in proper position.

In Fig. 1 I have shown one of the matrix boards A of the lowermost course, that next to the angle in the wall, removed and used above in place of one of the matrix boards A the stay rods C having been unpinned and elevated to release the said matrix board and to connect the spreader bars and matrix boards of the up aer courses. This illustrates my method of removing the matrix boards of the lower courses as the concrete becomes sutficiently set to bear the weight, and reinstalling the boards above as the structure rises.

When the stay rods have been elevated to release a course of matrix boards and the boards have been removed; the now disused spreader bars are driven out and removed, leaving transverse slots 7 in the wall which are filled and pointed with fluid concrete.

The matrix boards of a course are preferably removed before the surface of the concrete has fully set, so that the exposed surface may be smoothed and finished by floating.

It will be noticed that the holes 1 in the spreader bars B are provided in pairs so that the bars may be engaged by two stay rods C at each end, as shown in Fig. 1. This aids in properly centering and levelling the matrices and also enables me to use stay rods of convenient length, the lower ends of the upper stay rods C overlapping the upper ends of the lower stay rods C and thereby preventing a loss of stability.

In starting the wall I prefer to use a pair of stay rods connecting each end of the pair of upper and lower spreader bars to insure stability and prevent vertical misalinen'lent or deflection.

If desired the stay rods, at least after the lower courses are cast, may be supported by a pin thrust through a hole 1 in the rod and resting upon the top of an upper spreader bar, as shown in Figs. 4 and 5.

It will also be noticed that an extra pair of holes 1 are. provided stepped out toward the end of the spreader bars. By this means the stay rods may be shifted outwardly and the matrix board or boards stepped out to form a window sill, door lintel or other basrelief in the wall requiring a projection or greater thickness of wall.

The inner or working faces of the matrix boards may be plane to form a smooth surfaced wall or may be given an irregular or other surface, such as to form imitation stone or brick work. Where the wall is to be given a surface resembling stone or brick work, I may advantageously use a metal matrix plate, such as A in Fig. 15, the same being preferably of light weight and strengthened by the edge and transverse ribs 9. The ends of the plate A may be provided with hook projections 9 for the application of the angle members I] at the corner.

The manner of forming a wall end in accordance with my system is shown in Figs. 16 and 17. In such cases the matrix boards A which are used to form the sides of the wall extend beyond the end thereof and a spreader bar B is inserted up into the notches 5 in the lower edge of the wall, said Inn boards being provided with such notches next to the wall end.

The short end matrix board A is now slipped down between the boards A. in proper position to define the end of the wall and the stay rods C are placed in position with their lower ends stepped in the holes 1 in. the spreader bar and pinned in place. A top spreader bar B is new lowered in place on the top of the boards A with the stay rods C extending up through its corresponding holes l and pins 10 driven into properly placed sockets in the upper edges of the boards A to hold the top spreader bar l)" in place to sustain the end matrix board A in proper position. The concrete is then filled in to form the wall including its end portion and levelled off horizontally, flush with the tops of the A. and A The next course of matrix boards A are then placed in position as before, the next set of spreader bars placed on top of the same and the stay rods pinned thereto. lit the end a second end matrix board is placed in proper position between the newly placed side matrix boards, a second spreader bar is placed on top of the side matrix boards, with stay rods C extending up through and pinned in its holes 1" and the spreader bar is then held against outward movement by the abutment pins 10 extending up from sockets in the top edges Of the side matrix boards.

In l ig. 12 the position of the holes 1 relative to the ends of the spreader bar and its holes 1 is illustrated To enable the spreader bar to be engaged by additional end stay rods, I provide additional holes 1 inside the holes 1 so that as shown diagrammatically in Fig. 17 an intermediate end spreader bar B is engaged from below by the stay rods C" and from above by the stay rods (3*, the former being pinned in the ho es 1" while the latter are pinned in the holes 1.

l prefer to use a cellular construction for the walls for the purpose of making the saine drier and warmer, and also to effect a economy in material. Thislprefer to accomplish by interposing form members in the wall while the latter is being cast, using either hollow metal forms which may re main in the wall or blocks which are removed as the wall is built up beyond them.

Thus in Figs. 1, 2 and 3 I show the use of oldtin cans F which may be built into the wall, assembled. in vertical columns as shown. The rusting oil the cans is prevented when they are embedded, and, in addition to the air spaces thus formed, the metal acts as a reinforcement against tension and shearing strains in the wall; strains which the concrete is least able to resist in itself. I prefer to space apart the ends of adjacent or alined cans thus breaking up the hollows into isolated cells.

In Fig. 6 I show the cans assembled alternately in batteries and single, while in Fig. 7 the cans are in staggered relation. I prefer to arrange the cans so that they will break joints between the courses oi masonry, thereby reintorcing the union between adjacent courses.

in l 8 I show the use of wooden or other solid terms or bloclrs G which are hit ed from place when the concrete has set around them, thereby leaving hollows or recesses in the walls. In Fig. 8 I show plates H used to cover the hollows formed by the blocks G, after the latter have been removed, thus preventing the filling up of the said hollows by the further rise of the wall. 'llhese plates also act as reinforcements for the comrele of the wall.

ln Fi S) I show the means for embedding an ornamental tile or other preferred element in the wall. Thus I is a tile held in position against the working :tace of the matrix board A by means of pins 12. When the wall is cast and has set the board is pulled away leaving the tile l embedded in the face ot the wall, and the pin holes in the wall are then filled up.

l requently it is desirable to form the body wall of ordinary concrete mixture while one or both exposed surfaces are to be of a finer grade of plastic, such as marble, screenings or white concrete. In such cases I provide an inner wall plate J of thin metal, set back from the matrix plate A so that the body of the wall may be cast between said inner wall plate and the back matrix plate while the thin facing layer or" liner material may be cast between the plate J and the adjacent matrix plate A. When the layers are cast, the plate J may be withdrawn and the two layers oi? material will move together and unite integrally as they set. To support the partition plate 5 in position I prefer to provide the spreader bars B with a pair of notches 18 at the proper point and also notch the bottom edge of the plate J so as to fit down over the braces B and interlock with the notches 13. At the top I use metal holders li provided on their bottom edges with wider recesses 1-l to fit over the top edge of. the board A and a properly positioned narrower recess 15 to engage the top edge of the plate 5. The holders are preferably provided with handle loops 16. Thus the partition plates .l are readily set in position and may be quickly pulled out when the backing and facing have both been cast.

It is evident from the "foregoing that my improved system greatly reduces the time, labor and materials required for concrete construction work. The matrix boards, cross braces and stay rods are cheap to manufacture and may be employed over and over again repeatedly. In case wooden matrix boards are used, the same may be cut lot) to the desired lengths on the job and later be utilized as sheathing or for other purposes on the job. The elements are easily transported and handled, and unskilled labor may be used for making the concrete structure therewith.

Thus a building or other concrete structure may be erected at greatly reduced cost, including labor and in much less time than by either of the present methodsthat of casting the structure in whole or in section on the job or of erecting the structure of premade concrete units.

It is quite evident that my system makes the wall self centering and self levelling, since, it the wall is started on a truly horizontal surface each course will be provided with a top surface truly parallel with the basic surface and with its sides truly vertical. Thus the system can be worked with unskilled labor, as no careful watch is required to keep the structure true and level but these ends are automatically accomplished as the work proceeds.

The method of forming internal cells in the monolithic wall is very advantageous and increases the strength and rigidity oi the structure. I am enabled to use with great advantage waste material, such as discarded tin cans, and their badly rusted condition is no draw back as their further rusting is prevented when embedded in the concrete.

My system also enables me to impart an improved ornamental surface to the structure. Thus I may smooth finish the same by floating. In the case of ornamental surfacing by a layer of fine material, the same may be formed in a much more satisfactory and permanent manner than by trowelling or spreading the plastic layer on the concrete.

By the use of my system greater scope or elasticity of construction is obtained, as window sills, lintels, wall irregularities and ornamental inserts are readily provided for without the use of special forms or devices.

One marked advance over the prior art is the provision oi a cellular-monolithic wall as contrasted; on the one hand with a composite wall formed by assembling hollow units or blocks, an expensive and time consuming method, and, on the other hand, with a solid or hollow monolithic wall. My cellular-1nonolithic wall or other structure is much cheaper than the structure built up of blocks and may be erected much more rapidly, and it is much dryer and more efficiently insulates against changes in temperature than does the solid monolithic structure.

Many other highly advantageous features will appear to those skilled in the art.

Although, for the sake of clearness, I have described in detail the embodiment of the principles of my invention which is shown in the drawings, 1 do not wish to limit myself thereby, but claim broadly 1. A matrix for concrete construction comprising a plurality of superimposed pairs or" matrix boards, the two boards of each pair being spaced apart to determine the thickness of the wall to be cast, transversely disposed spreader bars interposed between superimposed pairs of matrix boards with their ends protruding, the pro-- trading ends 01 said bars being provided with a pair oi holes transversely alined on said bars, vertically disposed stay rods having their ends inserted in said holes and which rods support the matrix boards from without, the stay rods for different levels of said matrix being inserted in different holes in said spreader bars whereby the matrix may be built up to the desired height and the stay rods in the lower levels may be removed to permit the removal of the lower matrix boards as the concrete sets.

2. A matrix for concrete construction comprising a plurality of superimposed pairs of matrix boards, the two boards of each pair being spaced apart to determine the thickness of the wall to be cast, transversely disposed spreader bars interposed between superimposed pairs of matrix boards with their ends protruding, the protruding ends of said bars being provided with a pair of holes transversely alined on said bars, vertically disposed stay rods having their ends inserted in said holes and which rods support the matrix boards from without, the stay rods for different levels of said matrix being inserted in difi erent holes in said spreader bars whereby the matrix may be built up to the desired height and the stay rods in the lower levels may be removed to permit the removal of the lower matrix boards as the concrete sets, and said spreader bars being provided at each end with a plurality of pairs of holes to provide for different widths of matrix whereby the thickness of the wall may be increased or diminished as desired.

3. A matrix for forming a concrete Wall having an end portion con'iprising a plurality of superimposed pairs of matrix boards, the two boards of each pair being spaced apart to determine the thickness of the wall and said boards extending horizontally beyond the end of the wall, trans versely disposed spreader bars interposed between superimposed pairs of matrix boards with their ends protruding, the protruding ends of said bars being provided with holes, vertically disposed stay rods having their ends inserted in said holes and supporting the matrix boards from without, additional spreader bars interposed between the superimposed matrix boards at the wall ends, said last named spreader bars being spreader bars, and cross matrix boards inserted between the first named in atri 2;

boards at the Wall end and bearing outwardly against said last named spreader bars.

Signed at Knoxville, Pa, this 9th day of Jany. 1922.

OTIS A. HOLLIS. 

